Elevator and Drag Chains. Cement Industry Chains and Accessories

Transcription

1 levator and rag Chains Cement Industry Chains and ccessories

2 he Leader in levator Chain esign Simply stated, an elevator chain must provide predictable wear life for the longest time possible. his factor is critical in elevator chain design to allow for planned maintenance and elimination of costly downtime. on t risk your production with an elevator chain not designed specifically for demanding cement mill elevator service. Rexnord elevator chains are designed and manufactured by Rexnord Industries, Inc., a leader in the manufacture of heavy duty bucket elevators for cement mill service. Coupled with over 100 years of chain manufacturing experience, you can be assured that we know how to maximize elevator chain performance. he reatest atigue Strength ucket elevators are fatigue machines that generate millions of load cycles. or example, a chain elevator with 70 ft. (21.3 m)centers operating at 300 PM (1.5 m/s) could see over 1,000,000 load cycles in just one year of service! Precisely for this reason, all Rexnord elevator chains are designed with a primary objective of providing the maximum fatigue strength that is possible. Only Rexnord has the combination of design engineering, manufacturing technology and product testing to keep advancing the art of high fatigue strength chain production. We have tested competitive chains and, size for size, none match the fatigue strength of Rexnord elevator chains. he Longest Wear Life Rexnord leads the industry with its induction hardening and deep case carburizing capabilities. s a result, Rexnord elevator chain pins and bushings have the hardest and deepest case depths providing maximum wear life. In addition, Rexnord chains provided consistent wear over the life of the chain. his allows the user to predict the wear life of the chains, allowing for chain replacement as part of their preventive maintenance programs. his eliminates costly, unexpected maintenance and down time. 2 (5014) Rexnord Industries, LLC, 7/2009

3 he Rexnord Chain Story lot goes into a Rexnord chain that is not visible on the surface. he precision of a pin diameter or the case depth of a heat treated pin can only be realized after an in-depth analysis. Rexnord regularly tests our chains as well as competitive chains and it is clear that all chains are not created equally. Rexnord heavy duty cement mill elevator chains are made to provide the utmost in performance and dependability. Maximizing atigue Strength hrough it and inish Rexnord s 100 plus years of documented testing and application experience drives the development of elevator chain designs used to meet the cement industry s need for improved fatigue strength. ut design is only the beginning. Making these chains requires a major advancement in manufacturing technology to achieve: Controlled and repeatable interference fits Superb surface finishes he use of finite element analysis helps us develop and maintain our position as industry leader Chain Stress Maximum stress both chains see at head shaft. Low interference Rexnord Chain fit chain mount of stress change occuring during operation reprsented by Shaded reas mount of stress change occuring during operation reprsented by Shaded reas eneficial residual stress on chain at all times. Zero stress on chain when it is at the boot. Controlled Interference it hrough Precision Components One of the main reasons for the durability of a Rexnord elevator chain is the optimum interference fit we achieve after assembly. he interference fit of pins and bushings creates a beneficial residual stress around the sidebar holes to significantly improve fatigue life. o illustrate the importance of interference fit the following graph shows the range of stress that two chains might experience in an elevator as they travel from the loaded to unloaded conditions in a bucket elevator. he red line shows a low interference fit chain and the blue line shows a Rexnord chain with a controlled interference fit. he low interference fit chain starts from a zero loading position, reaches a maximum load at the headshaft, and drops back to zero at the tailshaft - a large change in stress. he Rexnord chain has a narrower change in stress as it starts from a higher pre-stressed level, due to the controlled interference fit, rather than the lower stress level starting point of the low interference fit chain. Over many cycles, the change in stress will lead to fatigue failures. he larger the change in stress, the greater the chance that the steel may break down and cause a chain failure without warning! Rexnord Industries, LLC, 7/2009 (5014) 3

4 Controlled interference fit comes from manufacturing components with very precise tolerances. If part diameters are not kept within a very close range, some links will have too much interference fit and others will have too little. Rexnord has spent years testing interference fit to find the optimum level for elevator chains. ll Rexnord elevator chains are applied based upon fatigue curves generated from this testing. o control the amount of interference, Rexnord uses the most advanced machine tools available today. hese statof-the-art machines yield chain pins and bushings with extremely accurate and repeatable diameters. Sidebar pin and bushing holes are made using advanced piercing techniques to produce precise hole diameters. No one but Rexnord has invested so much in time, testing, and equipment in the pursuit of excellence in chain manufacturing. Super Smooth Hole inishes In addition to controlling tolerances, sidebar hole and component surface quality is a significant part of optimizing a chain s fatigue strength. Many chain failures occur from tiny imperfections in and around the pin and sidebar holes. hese imperfections result in stress concentrations that, over time, become cracks that slowly propagate with each cycle in the elevator. ventually, these cracks lead to a sudden chain failure. Rexnord has developed advanced piercing techniques that ensure a smooth hole surface finish. s an additional step, all sidebars are shot-peened to remove surface imperfections and create beneficial residual surface stresses. Maximizing chain wear life through science and craftsmanship Rexnord leads the chain industry in heat treatment technology. Computer controlled furnaces and Rexnord designed induction heat treating equipment produce chain components with the hardest and deepest cases available. Specialized equipment is used to heat treat sprockets and traction wheels. Rexnord s specialized carburizing and induction heating equipment for these accessories is not matched in the sprocket market! 4 (5014) Rexnord Industries, LLC, 7/2009

5 I K I K CHIN PICH SYL CHIN PICH SYL Chain Number Pitch Style K Centrifugal levator Chain imensions Sidebars Pins ushings H R H R I H R SPROCK NUMR R H 1.00 CIH CR R H 1.00 CIH CR R H 1.00 CIH CR R H 1.13 CIH CR R H 1.25 CIH CR R H 1.25 CIH CR R H 1.38 CIH CR R C H 1.62 CIH CR Consult with Rexnord engineering for elevator chain selection and application. H: hru-hardened CIH: Circumferential Induction Hardened after thru-hardening CR: Carburized imensions shown are in inches. Red dimensions are millimeters imensions are subject to change. Certified drawings are available upon request. 800 Series and 900 Series levator chains Rexnord introduced the original 800 Series of elevator chains in the 1950 s. he strength and wear resistance provided by these chains allowed elevators to be built taller and run faster than ever before. Rexnord continues to increase the performance of the 800 Series through improvements in manufacturing technology. he 900 Series of chains was created to provide even more strength than the present 800 series. Rexnord gave the 900 Series larger components to provide a minimum of 30% greater fatigue strength. his greater strength may be used for additional capacity in new elevators, or it may be used to provide a low cost solution to an existing elevator problem. oth the 800 and 900 Series are produced to the same high quality and premium performance specifications. he 900 Series conveniently interchanges with the 800 Series chains. Now upgrading your elevator can be as simple as replacing your chain! Contact Rexnord for application assistance. R856 versus R956 enefit: Provides 30% greater fatigue strength. Operates on same traction wheel and sprocket. ucket hole spacing is identical. R857 versus R958 enefit: Provides 30% greater fatigue strength. Operates on same traction wheel but sprockets are different. ucket hole spacing is identical. R864 versus R984 enefit: Provides 30% greater fatigue strength. Operates on same traction wheel but sprockets are different. ucket hole spacing is identical. Rexnord Industries, LLC, 7/2009 (5014) 5

6 H K35 K2 9/16 H K3 C C H K24 H K44/443 9/16 C J K C C Centrifugal levator Chain ttachments Chain Number ttachment Style C H J K Weight* R856 R956 R857 R859 R958 R864 R984 R1084 R856 R856 K24 K44 K443 K2 K3 K Consult with Rexnord engineering for elevator chain selection and application. H: hru-hardened CIH: Circumferential Induction Hardened after thru-hardening CR: Carburized imensions shown are in inches. Red dimensions are millimeters imensions are subject to change. Certified drawings are available upon request. 6 (5014) Rexnord Industries, LLC, 7/2009

7 Rexnord xclusive Pre-lubricated Sealed Joint levator Chains Rexnord s patented seal keeps grease in and abrasive materials out of the chains joint to significantly improve chain joint life. his unique design couples a resilient seal (blue) with a hardened steel retaining ring (red) to completely seal off the chain joint from fine abrasives. qually as important, the seal retains factory installed grease (green) in the chain joint to dramatically reduce the wear of the chain. Nothing else in the industry comes close. Hardened Steel Retaining Ring actory Installed rease Resilient Seal When to Consider the Sealed Joint Option Sealed joint chains are more expensive than standard chains. herefore, some forethought must be given to the proposed application so that the greater expense justifies itself. Severe pin wear in finished cement elevators or pin corrosion due to corrosive environments can be reduced with the sealed joint. he standard seal is limited to 250 (121 C). higher temperature seal material is available. Rexnord engineers are available to discuss any applications you may be considering. vailable Chains Many elevator chains are available with this option. Sealed joint chains have a SJM prefix that replaces the R prefix. s an example, to order an R984 as a sealed joint chain one would describe it as SJM984. Straight sidebar drive chains and many other straight sidebar conveyor chains are also available with this option. Let us work with you to tailor a chain for any problem applications you may have. Rexnord Industries, LLC, 7/2009 (5014) 7

8 Rexnord Heavy uty rag Chain made in the US Reduce maintenance and downtime with Rexnord heavy duty welded drag chain while increasing your conveying efficiency! his premium performance drag chain features: Hardface welding on both of the chain s sliding surfaces as standard. typical weld hardness of 58 Rc and a heavy weld bead give this chain excellent wear resistance in cold clinker applications. Interference fit between the pin and chain sidebar dramatically improves chain strength and joint wear life over that of cast drag chain. No loose pins to move around the chain joint. n Induction Hardened pin gives the best of two worlds a 60 Rc typical case and tough, impact resistant material in the balance of the pin. he result: wear resistance coupled with impact resistance. Square edges on the wing and sidebar or welded drag chain conveys more efficiently than rounded cast chain edges and moves a deeper bed of material with each revolution of the chain. Heat treated and fabricated steel components eliminate the failures that cast chains experience from casting porosity and inclusions. CHIN PICH IRCION O RVL Chain Number WHX5157 WHX6067 WHX5121* WHX6121 Pitch Sidebars Heavy uty Welded Steel rag Chain Heat reat Pins Heat reat Rated Working Load " ,200 H SIH , " ,300 H CIH , " ,600 H CIH , " ,600 H CIH ,000 Sprocket Number *WHX 5121 is dimensionally the same as WHX 6121 except it runs closed end forward. H: hru-hardened CIH: Circumferential Induction Hardened after thru-hardening CR: Carburized imensions and working loads are shown in inches and pounds. Red dimensions and working loads are in millimeters and newtons. imensions are subject to change. Certified drawings are available upon request. 8 (5014) Rexnord Industries, LLC, 7/2009

9 Continuous ischarge ual Strand levator Chains H I K CHIN PICH CHIN PICH 5 ttachment Style I K 4000 Series Chain he 4000 series chain is a 12 pitch chain that utilizes only one pitch per bucket. Rexnord s all-steel fabricated chains are precision built with high quality steel that incorporates advanced heat treating methods to prolong wear life. he chain is then matched in pairs for true dual performance with end hung buckets. It is furnished with 118 attachments. CHIN PICH CHIN PICH I 118 ttachment Style H K 4100 Series Chain he 4100 Series is a 9 pitch chain that utilizes 2 pitches per bucket. It has all of the features of the 12 pitch chain, but the shorter pitch permits higher speeds which means greater capacities. he 4100 series chain is furnished with either a 5 or a 6 attachment. CHIN PICH CHIN PICH.812 I HOLS ttachment Style Chain Number Pitch K Continuous ischarge ual Strand levator Chain imensions Sidebars Pins Rollers ushings Rated Heat Heat Heat Heat Working 2 H I reat reat reat reat Load Sprocket Number R H 0.88 CR 1.75 CR CR 9, ,000 R H 1.00 CIH 3.00 CR CR 12, ,500 R H 1.25 CIH 4.25 CR CR 18, ,000 R H 1.50 CIH 4.50 CR CR 29, ,255 R has.56 inch diameter countersunk bolt holes R has.81 inch diameter countersunk bolt holes H: hru-hardened CIH : Circumfrentially Hardened after thru-hardening CR: Carburized imensions and working loads are shown in inches and pounds. Red dimensions and working loads are in millimeters and newtons. imensions are subject to change. Certified drawings available upon request Rexnord Industries, LLC, 7/2009 (5014) 9

10 Rexnord Components Matched for high performance Casings: Head Sections Rexnord Super Capacity elevators are designed with a split, removable upper head section manufactured of #12 gauge steel with dust seals to seal shaft openings. his design also incorporates channels that ring the lower head section to help form headshaft bearing support helps to insure proper bearing life and maximum machinery life. Our lower head section casings are all jig welded and are fabricated from ¼ (6 mm)steel with heavy structural stanchions under the bearing support ring. he discharge chute is fabricated of #7 gauge steel with a 3/8 (9.5 mm)bottom plate for wear resistance. he Head section also includes easy access doors for discharge lip inspection and maintenance. Clawmaster Chain assembly tool Keep the advantage of the high interference pin fit by using the ClawMaster assembly and disassembly tool for all Rexnord elevator chains. Use of this tool eliminates pin grinding or the heating of side bars which destroys the fatigue strength of the chain and can result in premature chain failure. his rugged device incorporates an improved arm design that helps reduce breakage and increases power by 2 ½ times by using a hydraulic ram and hand pump to deliver the extremely high forces necessary to drive chain pins in the field or in the shop. he holes in the arms aid in handling the tool by providing key anchor points for crane lifting or manual handling. his tool can be used for efficiency in both chain assembly and disassembly. Request bulletin No for more details. levator uckets Over 80 years of elevator design gives us practical application experience that we have used to help design our buckets. Rexnord Super Capacity Style C and CS buckets are designed to elevate and properly discharge a wide range of bulk material. uckets are fabricated from 7 gauge steel plates and the use of deep continuous welds to assure high strengths for severe service applications. Other thicknesses are available upon request. o meet your specific needs, buckets are available with R wear lips and non stick liners if needed. HL buckets are continuously mounted and end hung on two strands of chain with bearing plates which redistributes the load to avoid cracking at the bolt holes. 10 (5014) Rexnord Industries, LLC, 7/2009

11 oot Sections: he Rexnord Super Capacity elevator boot section is fabricated from ¼ (6mm) steel plate with a detail on the heavy corner angles that are jig welded to assure that the elevator is given a square and dimensionally true beginning assembly point. Removable front and rear clean out panels, along with large double-hinged access doors make inspections and cleanouts simple. he Rexnord gravity take up with a built in counter weight are standard equipment as well as the take up hoist beam for maintenance use. Segmental Sprockets Segmental sprockets are easily installed, simplifying replacement without disassembling body, chain or shaft assemblies. Heavy-duty solid steel rim sprockets are factory fastened to the body using Huck fasteners, offering positive rim/ fastener retention without concern of loosening during operation. Sprocket rim segments are made to wear-resistant specifications, deep carburized and induction hardened to 60 RC. Sprocket segments are reversible for double life. Head shaft assemblies are furnished with solid bodies utilizing keyless locking ring assemblies as standard in high performance elevators. Keyless locking rings insure positive wheel retention to shaft without stress points associated with keyed shafts. Rexnord Planetgear Shaft Mount Planetary (SMP) he Rexnord Shaft Mounted Planetgear (SMP) Reducer Series is a perfect alternative to traditional helical shaft mounted reducers. he new SMP Series incorporates all the standard Planetgear features you ve come to expect for your heavy duty applications. he self-aligning gear train in contact per reduction equally share the load, and is directly mounted on the driven shaft, eliminating the need for a low speed coupling, chain drive or reducer mounting base. Our new Hercules reducer expands our offering to applications requiring output torque up to 2.9 million lb-in. Segmental raction Wheels ll the heat treat and hardening expertise that goes into our chain is applied to Rexnord s traction wheels and sprockets. matched set of traction wheels assures a smooth system operation. Plus, Rexnord s unique ability to achieve deep and hard case depths provides the longest wearing components available. on t settle for a substandard drive component when you purchase a premium elevator chain. Ni-Hard earings Cast Ni-Hard take up bearings and Ni-Hard sleeves require no lubrication and no periodic maintenance, thus ensuring a long service life and less maintenance headaches. Rexnord Industries, LLC, 7/2009 (5014) 11

12 World Class Customer Service or more than 100 years, the dedicated people of Rexnord have delivered excellence in quality and service to our customers around the globe. Rexnord is a trusted name when it comes to providing skillfully engineered products that improve productivity and efficiency for industrial applications worldwide. We are committed to exceeding customer expectations in every area of our business: product design, application engineering, operations, and customer service. ecause of our customer focus, we are able to thoroughly understand the needs of your business and have the resources available to work closely with you to reduce maintenance costs, eliminate redundant inventories and prevent equipment down time. Rexnord represents the most comprehensive portfolio of power transmission and conveying components in the world with the brands you know and trust. WORLWI CUSOMR SRVIC USRLI Rexnord ustralia Pty. Ltd. Picton, New South Wales Phone: ax: alk-rexnord ustralia Pty Ltd roadmeadow New South Wales Phone: ax: RZIL Rexnord Correntes Ltda. Sao Leopoldo - RS Phone: ax: CN Rexnord Canada Ltd. Scarborough, Ontario Phone: ax: CHIN Rexnord China Shanghai, China Phone: ax: UROP Rexnord NV/S Mechelen, elgium Phone: ax: LIN MRIC Rexnord International Milwaukee, Wisconsin Phone: ax: mail: [email protected] MXICO Rexnord S.. de C. V. Mexico, Mexico Phone: ax: SINPOR Rexnord International, Inc. Singapore City, Singapore Phone: ax: UNI SS Customer Service Phone: 866-Rexnord ( ) -mail: rexnordcs(state)@rexnord.com xample: [email protected] LL COUNRIS NO LIS OV Rexnord International Milwaukee, Wisconsin Phone: ax: mail: [email protected]